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Dave Stephens

WIP: Two 6th Century Ring Hilt Saxon Swords

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Nice pic, good to see some scale :) Thanks Petr!

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Today I welded up the middle bar for the first sword. Here are some progress pics:

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/e-9utRSEw4eIf8JqDRD41g?feat=embedwebsite"><img src="http://lh4.ggpht.com/_H2LYpmX7-hY/TEtIuz7JtnI/AAAAAAAAAwE/ZgBT-zHg3VU/s800/CIMG2249.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>The starting stack. 12 layers of 15n20 and 1095. Stack is 2" wide, 1.5" tall and 4" in length. (Yeah, I know, lousy welding job . . )

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/8GfVWsJkXjBHd6hw2_sCFw?feat=embedwebsite"><img src="http://lh6.ggpht.com/_H2LYpmX7-hY/TEtIvVk1VUI/AAAAAAAAAwI/gMPDWPwgW5I/s800/CIMG2259.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Soaking.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/MxNgqQXQ4oKwvb097SUTJA?feat=embedwebsite"><img src="http://lh5.ggpht.com/_H2LYpmX7-hY/TEtIv3ZamCI/AAAAAAAAAwM/xDSK_ggHDHU/s800/CIMG2261.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Mid way into the drawing process.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/ySuQ9RbmDSC6-LeDs53lWA?feat=embedwebsite"><img src="http://lh5.ggpht.com/_H2LYpmX7-hY/TEtIxXgYh9I/AAAAAAAAAwQ/dIF7P-PeZrQ/s800/CIMG2262.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Drawn out to about 28 inches.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/hLYgPp6mtbawB3vLJboLfw?feat=embedwebsite"><img src="http://lh3.ggpht.com/_H2LYpmX7-hY/TEtIyspVw7I/AAAAAAAAAwU/PZmJiBRtzCI/s800/CIMG2264.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>After getting the bar rough drawn with the press, I use the rolling mill to ensure uniform thickness. Here I am using a 1/2" thick chunk of steel to set the gap between the rollers.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/Wru3iW0ZvISGw27B3O0pHA?feat=embedwebsite"><img src="http://lh6.ggpht.com/_H2LYpmX7-hY/TEtIEORCOxI/AAAAAAAAAv4/nLZskG8pAOg/s800/CIMG2266.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Here's a video of using the rolling mill. Hit the mute button or turn your volume down. You just hear the forge and it sounds like static. Sorry for the poor video. I just had to set the camera on a stool and hit the start button.

 

Click the image to see the video.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/8NGfd6VeIwT27s9rpEUnrg?feat=embedwebsite"><img src="http://lh4.ggpht.com/_H2LYpmX7-hY/TEtI0H8MinI/AAAAAAAAAwg/dZdkYeo1RBM/s800/CIMG2268.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Almost there.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/ecHcuySJMxNEpuvalPOweQ?feat=embedwebsite"><img src="http://lh3.ggpht.com/_H2LYpmX7-hY/TEtI1NdPmuI/AAAAAAAAAwk/i_pWcAccDVk/s800/CIMG2269.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Drawn out to 38 inches. The blade will be 30 inches. 35" OAL. I figured 38" so I could chop a little off the ends for solid welds all the way through.

 

This bar will be the serpentine one in the middle. Next step is to twist it in alternating 90 degree twists using the Pringle technique. This will be my first attempt at that pattern, so wish me luck. I will post photos of the success or failure.

 

After this bar I create the two twist bars, and then the low-layer edge bar. Then weld everything together and grind out the blade. Then, start over again for blade #2!

 

I've decided, by the way, to make each blade individually rather than create two of each element. The latter would be more efficient, but would be much more tedious I think.

 

Advice, critiques, etc. always welcome.

 

Cheers,

 

Dave

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First it was Ealdric , which gave me a complex . Now this , which will make me go hide in the corner . Just pickin Dave .

I have seen a few things from some of you , that I really hope will someday be displayed for people to see , so they can marvel at the art of steel . What might go through somebody's head while they gaze at the work some of you are doing now ?

I think the ancient art is in good hands .

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looks awesome. Good luck on the serpent. Did you draw that by hand or with your press?

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looks awesome. Good luck on the serpent. Did you draw that by hand or with your press?

 

With the press. That would have been a lot of work by hand.

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With the press. That would have been a lot of work by hand.

Yeah i was wondering if you were only typing with one hand because your other arm fell off

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Dave this is just the kind of project you need. It's going to shoot your skills and confidence to the moon dude. It's both within your reach and just a bit beyond it at the same time; Perfect. Now go have some fun!

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today i casted one ring for hilt, its silver, mold was soapstone but the central part did not survived.

I will make other form for second ring

hiltring.jpg

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Very cool, Petr.

 

The twist bars will be welded up this weekend. I will post photos.

 

I will be on the road for almost two weeks starting next Wednesday, however, so the project will be paused a bit.

 

It is my goal to have the first blade finished and in Petr's hands by October 1.

 

Cheers,

 

Dave

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i will be off too! going to Ribe vikinge centre live as viking for one week!

Dave you would like to send the blades one by one? just curious.

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i will be off too! going to Ribe vikinge centre live as viking for one week!

Dave you would like to send the blades one by one? just curious.

 

Petr,

 

Yes, I would prefer to finish each blade individually. While this may be less efficient, I would find that to be more enjoyable.

 

--Dave

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Petr, soap stone seems like a lot of work to me, have you tried cuttlefish bone or sand casting?

 

Richard

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richard - i did not, but i will try cuttle fish! thanks for that tip.

but - making soapstone mold took about 20 minutes :-)

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Update on progress:

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/rtvinbtJNVO3KmTjPw69-A?feat=embedwebsite"><img src="http://lh4.ggpht.com/_H2LYpmX7-hY/TFEaEfRBO0I/AAAAAAAAAxQ/0FFQOFlpHgM/s800/CIMG2271.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>A big billet for the two twist bars.

 

18 Layers, 2" wide, 4" long, 4.5" thick.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/S5_jtoJr_KAKESGCk0Yjuw?feat=embedwebsite"><img src="http://lh4.ggpht.com/_H2LYpmX7-hY/TFEaF0ej8gI/AAAAAAAAAxc/auXv4DYDx4k/s800/CIMG2275.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Soaking.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/l7TD74Usf-vFEQp1GQtJ_w?feat=embedwebsite"><img src="http://lh3.ggpht.com/_H2LYpmX7-hY/TFEaGnoz-AI/AAAAAAAAAxg/GOUVRZTo2Pg/s800/CIMG2276.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Still soaking . . . Mouse and my buddy Shane lending moral support.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/yrTw-TgSs8CFALMhyYTOsQ?feat=embedwebsite"><img src="http://lh5.ggpht.com/_H2LYpmX7-hY/TFEaHM7_x4I/AAAAAAAAAxk/qGyVkraNR1s/s800/CIMG2277.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>Mouse says: "Is that billet up to welding temp yet dad?"

 

More photos of the draw of the twist billets soon. . .

 

I also did the alternating twists on the serpentine bar today. Click the photo below to view the video.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/avQcVxLCqiELNrYCo-nFew?feat=embedwebsite"><img src="http://lh3.ggpht.com/_H2LYpmX7-hY/TFEatst38hI/AAAAAAAAAx0/iSHTrSq3jEI/s800/CIMG2273.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>A video of the 90 degree alternate twists.

 

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/XTV9_3VbIYYY6d5BZC-EgA?feat=embedwebsite"><img src="http://lh3.ggpht.com/_H2LYpmX7-hY/TFEaJuVnffI/AAAAAAAAAxw/s4SPKUDr_NQ/s800/CIMG2282.JPG" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/DaveStephens907/PetrColab?feat=embedwebsite">Petr Colab</a></td></tr></table>

The wavy bar. Next step is forging it square again.

 

More soon.

 

Cheers,

 

Dave

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cool work dave! I did the serpentine twists on a multibar sword and found like you did in your video its a max of 2 twists per heat! Induction heater with flexy wand would have been very cool for that operation!

 

I forged the bar back square on the 'diagonal' to give the twists on the face of the billet. I got a lot of elongation of the bar forging it back square, hope you dont end up to skinny!. I dont want to spam up your thread with pics of my bars, but drop me a pm if you want to see them, and ill send you some links.

 

Owen bush gave me a very cool tip for multibar cores, work them short and fat (say @24" long for a 30"+ blade) it gives more metal on the welded faces between the bars, and it will elongate as you work it!.

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cool work dave! I did the serpentine twists on a multibar sword and found like you did in your video its a max of 2 twists per heat! Induction heater with flexy wand would have been very cool for that operation!

 

I forged the bar back square on the 'diagonal' to give the twists on the face of the billet. I got a lot of elongation of the bar forging it back square, hope you dont end up to skinny!. I dont want to spam up your thread with pics of my bars, but drop me a pm if you want to see them, and ill send you some links.

 

Owen bush gave me a very cool tip for multibar cores, work them short and fat (say @24" long for a 30"+ blade) it gives more metal on the welded faces between the bars, and it will elongate as you work it!.

 

 

Thanks John.

 

By all means, post your pics on this thread. I find that these threads serve as mini-tutorials for folks, so I think anything that would help a future smith be successful in creating a blade like this would be good.

 

I also worried about the elongation. I'll be forging it square again today. If it does stretch too far I'll start over.

 

Thanks for the tip John.

 

--Dave

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An annoyingly out of focus picture of a 'left right' twisted bar, prior to being forged back square,. I used these bars as edging bars on a 4 core blade. I twisted them when they were short, about 18" long x 1/2" sq, they grew nicely when I forged them to about 3/8" sq for welding together

 

(a mistake I made with the 4 core bars, let them grow to much, and then had to grind them to fit together for welding, instead of just forging the high spots of the twists back in)

 

twistededgebar.jpg

 

another poor photo of the 'serpent' bar forged back to square, with a quick etch to see where the snake was hiding :)

 

edge1-1.jpg

 

this was the construction of the bar before 'serpent' twisting, its a very tightly twisted bar sandwiched between 2 pieces of 60 layers.

 

edge1.jpg

 

should really pull my finger out and finish grind the damn sword :rolleyes:

Edited by John N

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That's it, I gotta pin this one. B)

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Dave, how tall is the celling in your garage? it makes for a nice work space looks like 4 car?

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